Textile product



06f. 18,` 1966 D GUKSMANN 3,279,22l

TEXTILE PRODUCT :A A A a. A A ALLA" c ATTORNEY Oct. 18, 1966 D. GLIKSMANN TEXTILE PRODUCT" 5 Sheets-Sheet 2 Filed Feb. 24, 1964 ATTORNEYS Oct. 18, 1966 D GUKSMANN 3,279,22

TEXTILE PRODUCT Filed Feb. 24, 1964 5 Sheets-Sheet 5 INVENTQR WAV/ /mSW//y/l//V f y /f/ ATTORNEY5 United States Patent O M 3,279,221 TEXTILE PRODUCT David Gliksmann, Bronx, NY., assignor to Burlington Industries, Inc., Greensboro, FLC., a corporation of Delaware Filed Feb. 24, 1964, Ser. No. 346,941 9 Claims. (Cl. 66192) The present invention relates to a new and improved textile product and to a process for making such product. More particularly, the invention is concerned with certain unique improvements in Ithe products and procedures disclosed in U.S. Patents 2,890,579 and 3,030,786, the subject .matter of which is incorporated herein by reference.

The abovementioned U.S. patents relate to the so-called Malimo machine and textile fabrics made therewith. While variations are possible, these fabrics normally involve the use of three yarn systems, namely, warp, weft and knitting threads. A plurality of weft threads are simultaneously laid by the machine and warp threads are placed on top of the weft without interweaving. The knitting threads are then use-d to connect and lock the weft and warp threads in their relative positions by means of parallel rows of stitches forming .a series of loop chains which integrate the various components into a composite fabric suitable for a variety of uses.

Broadly described, the Malimo machine includes a weft laying mechanism which draws the desired nurnber of weft threads from lappropriate creels and simultaneously places these threads in full fabric width. A pair of parallel m-oving chains receive and hold these weft yarns at the selvedge points of return. Guide means are also provided `for laying the warp threads on top of the weft. FIhe thus arranged warp and weft threads are then moved past a plurality of sewing or knitting need-les which in-clude specifically designed slides cooperating with suitable latch wires and guide needles so as to connect the warp and weft threads by rows of chain stitches resembling knit loops, formed with the knitting threads. A layer of wadding or other loose material may be used in lieu of the weft or the warp threads to givebulk and body to the final product.

While the above described development offers certain advantages over other fabricating techniques, particularly as to manufacturing time and costs, there are also disadvantages attendant there-to. For example, it is not always possible to obtain a uniform and attractive product and it is particulraly difiicult to obtain desirable styling effects. This `is due, at least in part, t-o the fact that the weft (or lling) side was generally been relied upon for whatever' styling is to be obtained and it is not possible to obtain uniformity on this side because the operation of the weft-laying mechanism is such that the weft is laid ba-ck and forth across the width of the product to form groups of weft threads which .are angularly disposed to adjacent groups. Consequently, when stitching occurs, the weft thread-s are not uniformly stitched over the width and length of the product.

In view of the foregoing, the principal object of the present invention is to provide certain improvernnts in the preparation of fabrics by the methods referred to above whereby there is obtained a product having an unusually desirable styling elect, maximum uniformity and other .advantageous characteristics. Other objects will also be apparent from the following detailed description lof the invention and the accompanying drawings wherein:

FIGURES 1 Iand 2 are perspective views showing opposite sides of a product prepared according to the invention;

3,279,221 Patented Oct. 18, 1966 ICC FIGURE 3 is also .a perspective view of the fabric shown in FIGURES 1 and 2;

FIGURE 4 is a `diagrammatic side elevational view of one form of apparatus for practicing the invention;

FIGURE 5 is a perspective view of part of the apparatus shown -in FIGURE 4;

FIGURE 6 is an elevation view looking in the direction .of the arrows in FIGURE '5 with `certain parts removed for clarity; and

FIGURE 7 is a fragmental perspective view showing another form of product prepared according to the invention.

Broadly stated, the objects of the invention are realized, in accordance with one embodiment of the invention, by inserting a decorative or `style effecting woven or knitted fabric component between separate layers of warp and wett threads or yarns prior to stitching or knitting these yarns together. The thus inserted fabric component may have any desired con-struction and may include one or more natural, synthetic and/or semi-synthetic yarns depending on the end use which is intended. Advantageously, the fabric is printed, dyed or otherwise colored (e.g. it `may Ibe made from appropriately dyed yarn or it may be woven in patterns using either fancy Douby or Jacquard techniques). In any case, the cloth should be selected to give the desired styling or decorative effect preferably at least on the warp side while advantageously masking `or concealing the weft yarn. If desired, the warp and knitting thread may also be selected to further t-he desired styling eifect.

In practicing the invention, the cloth is stitched togcther with the warp and weft yarns or threads by means of loop chains or chain stitches formed with stitching thread according to the patents mentioned above. The end -result `is a textile structure characterized by unusual stability and style appeal and containing three, four, ve or more different yarn systems, depending on the construction of the cloth component. By chan-ging the product density, yarn sizes, quality, color and surface of any one or all of these yarn systems, including the fabric component, a wide variety of highly attractive styling elfects may -be obtained.

As a further modi-cation of the invention, either the warp or weft threads may be omitted so that the completed struct-ure comprises only one of said threads interlaced and bound together with the stylin-g fabric by means of loop chains or chain stitches.

As indica-ted, the knitting or stitching thread is used herein in the manner described in `said US. Patents 2,890,579 yand 3,030,786. In particular, the thread is laid on one face of the composite of warp, weft and fabric, preferably on the warp side, the thread being passed back and forth through the composite to form one Ior more parallel rows of interlocked loops or loop chains positioned -on the opposite face of the fabric and extending lengthwise thereof. To prevent running of a cha-in in case a loop is damaged or destroyed, each chain is conveniently made up of two threads which form alternate loops in the chain. In one way of forming such a chain, the two threads cross the composite structure together but at regular points across the surface, one thread is alternately pass-ed through the structure and looped around the other thread. In another modiiication, the loop chains may be made yusing two threads which alternately `form the loops of two Iadjacent chains. In this latter arrangement, the threads form an interlaced structure in which the threads cross a surface of the structure in zig-zag fashion.

The warp and/or weft yarns used herein may be any conventional textile material in the form of spun yarn or continuous filament yarn. Typical illustrations include Wool, cotton, polyester (Daeron), acrylics, nylon and rayon, or blends of any two or more of these materials. The warp and weft yarns may comprise the same or different materials and they may have the same or different construction. Additionally, in preparing the present products, the warp and weft yarns may cross each other at various angles although by the nature of the Malimo machine, these yarns cannot be perpendicular to each other. Also inherent in the operation of the Malimo machine is a variation in the angular disposition of adjacent groups of weft yarns as noted above. This leads to some nonuniformity on the weft side of the product as stated earlier but the present invention avoids any disadvantage in this by using as the fabric component one which gives the desired decorative or styling effect on the warp side of the composite product. This side may then be used as the face of the product while the weft side is hidden.

Referring now more particularly to the drawings, FIGURES 1-3 show how the various components are integrated to give a unified fabric of highly desirable stability, styling and other advantageous properties. The fabric component is shown by the numeral 2 and, in the embodiment illustrated, this component is positioned between separate planes of warp yarns 4 (FIGURES l and 3) and weft yarns 5 (FIGURES 2 and 3). As indicated earlier, the fabric component 2 is appropriately selected to give the desired styling effect or decorative effect and it may be made of the same material as the warp and/ or weft yarns or different material. In the embodiment shown, the warp side of the fabric component 2 includes an appropriate design 6 to give the desired appearance to the final product. The weft side of the fabric may be plain as shown in FIGURE 2 or decorated or styled as desired.

In a typical construction, the fabric insert or component may comprise single 36s Worsted count wool/polyester (Daeron) blend in warp and filling (e.g. 65 ends warp and 58 picks giving a 6-6.5 oz. cloth colored and/or woven in whatever pattern is desired). Obviously, other fabrics may be used and the type or types of warp and weft yarns, as well as stitching thread selected for combination with any particular fabric, will necessarily depend on the Weight and styling effect desired for the finished product. Broadly speaking, any apparel or decorative fabric may be used herein as the fabric insert or component and for convenience, this component is described generically herein as a styling fabric, it being understood that this is distinguishable from loosely woven gauze-type structures, bats of loose fibers or the like which have no styling or decorative function.

As shown in FIGURES 1 3, the warp, weft and fabric components are all held together to give an attractive composite product by means of parallel rows 7, S and 9 of interlocked loops or chain stitches formed with the stitching or knitting thread designated broadly by the numeral 10. In the embodiment shown in FIGURES l-3, each chain or row of loops includes two separate knitting threads. One of these threads lltla is passed through the fabric 2 at point x and then through a preceding loop Sb formed with the other knitting thread 10b. A loop 8a is formed and the thread is then drawn back through the fabric at the same point or substantially the same point x as it was passed through initially. The withdrawn thread 10a is then drawn over the surface of the fabric as shown by the segment 12 across the warp yarns 4a and 4b. Immediately beyond warp yarn 4b (to the left in FIGURE l), the thread 10a is again passed through the fabric and a preceding loop 9b formed on the other side of the fabric by knitting thread lltlc, looped as before to give the loop 9c and drawn back through the preceding loop 9b and the fabric from whence it is returned again to complete a loop in row 8. It will be seen that with this arrangement the interlocking loops of each chain alternately comprise different threads. Additionally, when a particular thread is not used to form a loop in one chain, it is used to form a loop in an adjacent chain so that each thread alternately forms a loop in one row of chain stitches and then a loop in an adjacent row. Thus, thread 10a alternately forms loops in the rows 3 and 9, while thread 10b alternately forms loops in rows 7 and 8 and thread 10c in row 9 and the next adjacent row not shown. As a result, the knitting threads lie in zigzag fashion over the warp 4 and fabric component 2 as shown in FIGURE l. Only two rows of stitches or chais are shown in FIGURE l, for the sake of simplicity although it will be appreciated, as indicated by the zigzag lines running across the entire surface of the fabric 2, that additional rows or chains are contemplated. Obviously, the number of such rows can be varied to give the desired integrity to the product.

FIGURE 3 illustrates in more detail the manner in which the warp 4 and weft 5 and intermediate fabric component 2 are intimately united by tht knitting threads 10a, 10b and 10c.

FIGURE 4 shows the conventional Malinio type apparatus as described in U.S. Patents 2,890,579 and 3,030,786 modified to include an appropriate source 14 of fabric 2 appropriately selected to give the desired styling effect. As shown, the fabric 2 is fed downwardly to the knitting station 16 where a laminate is formed comprising the fabric, warp yarn 4 and weft yarn 5. The weft yarn 5 is taken from an appropriate source (not shown), and fed downwardly through .guide 1S. The latter reciprocates back and forth between two parallel conveyor chains 20. By means of guide IS, the weft yarns are laid between the chains with the ends of weft yarn held in fabric width between the chains and moved thereby towards the knitting station 16. The warp yarn Il and knitting thread llt) are also fed to the knitting station 16 in the manner indicated from appropriate sources not shown. At station 16, knitting thread 10 knits the fabric component between the Warp and weft yarns in the manner indicated above to give the desired product 24 which is suitably collected as shown at 26.

FIGURE 5 shows in somewhat more detail the manner in which the warp 4, weft 5 and fabric component 2 are brought together for the knitting or stitching operation at station 16. It will also be apparent from this figure how the reciprocating movement of the guide 18 between the parallel chains 20 coupled with the movement of the chains angularly disposes adjacent groups of the weft yarns with respect to each other. The fabric component 2 is preferably fed into the machine so that the design 6 appears at least on the Warp side, as best shown in FIG- URE 6 Where the warp yarn has been omitted for clarity. Usually, the warp side is used as the face of the product although the design 6 may also appear on the weft side as shown by the broken lines in FIGURE 5 to improve the appearance of this side of the product.

FIGUR-E 7 illustrates another way of stitching together the components of the present product. As in the case of FIGURES 1 3, two stitching threads 28 and 30 are used but instead of alternately using each thread in adjacent rows as in the embodiment of FIGURES l-3, the threads 2S and 30 go straight across the warp side of the product, first one and then the other of the threads being passed through the composite and lbeing looped with a previous loop formed with the other thread on the weft side of the product.

It is believed that the distinctions and advantages of the present invention over prior procedures involving Malimo type operations will be apparent from the 'foregoing description. rIlhus, for example, in the prior procedures, it is the filling yarn which is generally used for whatever possible styling effect is obtainable and any components other than the warp and weft, e.g. loose bats or gauze, at most only serve to give strength to lthe product. In contrast, a styling fabric as contemplated herein, eg. a woven or knitted cloth, printed, yarn colored or ythe like, inserted for styling purposes, can be used to establish the warp side of the product as the Ltace thus concealing the weft ori-lilling side of the product with its inher-ent lack of uniformity.

As will be appreciated, the novel products of ythe present invention may be used in many ways, e.g. as upholstery, drapery and curtain materials. They may also be employed inthe manufacture of accessories such as handbags, shoes, or in the production of apparel such as suits, coats, sportswear and the li-ke.

Various modica'tions may be made in the invention described herein. @For example, diier-ent colors may be used in the warp and stitching thread, over and above the fabric insert, to give unusual and hitherto unobtainable eects. Other modifications are also contemplated as will be apparent from the following claims wherein:

I claim:

1. A textile product comprising a styling fabric positioned between separate layers of Warp and weft yarns, said styling fabric and said warp and weft yarns being interlaced and bound together into an integral structure by knitting thread forming a series of loop chains.

2. The product of claim 1 wherein alternate loops in each chain are formed with a different thread and each thread forms alternate loops in `two adjacent chains.

`3. The product of claim 1 wherein each series of loops is formed by two threads which extend lengthwise of the product across the warp side and alternately pass through the product to the weft side where they are looped with a previous loop of the other thread.

4. The product of claim 1 wherein said fabric is a lknitted fabric.

5. The product of claim 1 wherein said fabric is a woven fabric.

6. The product of claim 1 wherein said fabric has a colored design effect thereon.

7. The product of claim 1 wherein at least one of the warp, -lling and knitting thread comprises a decorative yarn.

'8. The product of claim 1 wherein said styling fabric provides a decorative and styling effect on the warp side of the nished product while masking the weft yarns.

9. The product `of claim 1 wherein said styling fabric provides a decorative and styling effect on the weft side of the nished product while masking the warp yarns.

References Cited by the Examiner UNITED STATES PATENTS Re. 25,749 3/1965 Mauersberger 6\684 1,816,416 7/1931 Willingham 66-85 2,331,290 10/ 19143 Amidon 66-191 2,890,579 `6/ 1959 Mauersberger 66-#192 3,030,7 816` 4/1962 Mauersbe'rger 66--84 3,079,778 3/1963 Kubelka et al. 6'6-85 3,134,248 5/1964 Kubelka et al 66--125 3,174,308 3/1965 Mauersberger 66-192I MERVIN STEIN, Primary Examiner.

DONALD W. PARKER, R. FELDBAlUM,

Assistant Examiners. 

1. A TEXTILE PRODUCT COMPRISING A STYLING FABRIC POSITIONED BETWEEN SEPARATE LAYERS OF WARP AND WEFT YARNS, SAID STYLING FABRIC AND SAID WARP AND WEFT YARNS BEING INTERLACED AND BOUND TOGETHER INTO AN INTEGRAL STRUCTURE BY KNITTING THREAD FORMING A SERIES OF LOOP CHAINS. 